KR102701559B1 - Control body for an electronic smoking article - Google Patents

Abstract

A control body suitable for use in an electronic smoking article, said control body comprising a shell (301) and a coupler (324) configured to connect the control body to a cartridge of the electronic smoking article, said coupler further comprising a power source (310) and an electronic circuit board (306) disposed between the power source and the coupler within the shell, said electronic circuit board (306) being disposed parallel to a central axis of the shell (310).

Description

CONTROL BODY FOR AN ELECTRONIC SMOKING ARTICLE

The present invention relates to an aerosol delivery device, such as a smoking article. The smoking article may be configured to heat a material made from or derived from tobacco or which may include tobacco to form an inhalable substance for human consumption.

Many smoking devices have been proposed over the years as an improvement or alternative to smoking products that require tobacco combustion for use. Many of these devices are intentionally designed to provide the sensation associated with cigarette, cigar or pipe smoking without producing significant amounts of incomplete combustion and pyrolysis products resulting from the combustion of tobacco. For this purpose, a number of smoking articles, flavour generators and medicinal inhalers have been proposed that use electrical energy to vaporize or heat volatile substances, or that attempt to provide the sensation of cigarette, cigar or pipe smoking without significant tobacco combustion. See, for example, the various alternative smoking articles, aerosol delivery devices, and heating sources set forth in the background art, including U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013/0255702 to Griffith Jr. et al., U.S. Patent Publication No. 2014/0000638 to Sebastian et al., U.S. Patent Application No. 13/602,871, filed Sep. 4, 2012 to Collett et al., U.S. Patent Application No. 13/647,000, filed Oct. 8, 2012 to Sears et al., U.S. Patent Application No. 13/826,929, filed Mar. 14, 2013 to Ampolini et al., and U.S. Patent Application No. 14/011,992, filed Aug. 28, 2013 to Davis et al., which are all incorporated herein by reference in their entireties.

It would be desirable to provide a smoking article which uses heat generated by electrical energy to provide the sensation of smoking a cigarette, cigar or pipe, and which does so without burning the tobacco to any significant degree, without the need for a combustion heat source, and without delivering significant amounts of incomplete combustion and pyrolysis products. Advances in the manufacture of electronic smoking articles would also be desirable.

The present invention relates to materials and combinations thereof useful in electronic smoking articles and similar personal devices. In particular, the present invention relates to a control body that may include one or more elements useful for improving the function thereof.

The control body may include an electronic circuit board therein, which is configured particularly for improved functionality of the device. For example, in some embodiments, the electronic circuit board is oriented to provide improved communication between the pressure sensor and intake air entering the device. This may include a coupler element having an external opening to allow outside air to enter the device and a pressure channel to communicate the pressure drop caused by the intake air to an isolated segment of the device comprising a portion of the pressure sensor. Such a coupler may be particularly useful for reducing or preventing movement of liquid from an attached cartridge through the coupler into the control body, and thus reducing or preventing contamination of the sensor or other electronic components present within the control body.

In some embodiments, a control body for an electronic smoking article according to the present invention may comprise an elongated shell having an interior, a proximal end, and an opposing distal end. A coupler may be present, the coupler having a body end that engages the proximal end of the shell, and an opposing connector end that is configured to releasably engage with a cartridge. In addition to a power source, an electronic circuit board may be provided that is positioned within the shell between the power source and the coupler. The electronic circuit board may include control circuitry, which may include, inter alia, a microcontroller, a microprocessor, and the like, and any additional control components suitable for controlling power delivery from the power source and any additional functions of the device. Additionally, the shell may have a central axis extending through the shell from the proximal end to the distal end, and the electronic circuit board may be oriented parallel to the central axis of the shell.

In a further embodiment, the control body can include a pressure sensor attached to the electronic circuit board (i.e., provided on the circuit board). The pressure sensor can be attached directly to the electronic circuit board, which can have a separation factor as further described herein. The interior of the shell of the control body can have a pressure-sensitive space and a pressure-sensitive space, a first end of the pressure sensor can be in fluid communication with the pressure-sensitive space, and a second end of the pressure sensor can be in fluid communication with the pressure-sensitive space. The body end of the coupler can have a wall, and the connector end of the coupler can have a through-center opening. Additionally, the coupler can have a pressure channel extending between the first end in fluid communication with the center opening and the second end opening through the wall in the body end of the coupler to be in fluid communication with the pressure-sensitive space. In some embodiments, the pressure channel can be integrally formed within the coupler. The control body may include a sealing member configured to form a hermetic seal around the pressure sensor and the second end of the pressure channel and thus form a depressurized space surrounding the opening at the second end of the pressure channel and the first end of the pressure sensor. Additionally, the sealing member may be in physical contact with the inner surface of the shell.

The coupler can have an air inlet channel in fluid communication with the central opening therein. In some embodiments, the air inlet channel can be formed entirely within the coupler body. An air inlet opening can be present on an exterior surface of the coupler and can be in fluid communication with the air inlet. A peripheral air flow path can extend from the exterior of the coupler (i.e., through the air inlet opening), through the coupler body, and through the central opening. The control circuitry of the control body can be configured to establish current flow from the power source when the pressure sensor detects a reduced pressure within the reduced pressure space relative to the pressure within the atmospheric space. In some embodiments, the electronic circuit board can be disposed entirely within the atmospheric space.

In a further embodiment, the control body may include one or more light emitting diodes (LEDs) attached to the electronic circuit board. At least a portion of the coupler may be optically transparent such that light from the LEDs may be visible through the coupler. Additionally, the control circuitry may be configured to cause the LEDs to emit a predetermined illumination signal corresponding to a state of the electronic smoking article. In some embodiments, the control body may include an input element. The control circuitry may be configured to cause the one or more LEDs to emit a predetermined illumination signal in response to an input from the input element. The input element may be a manual input element (e.g., a pushbutton or a touchscreen). In some embodiments, the input element may be at least partially optically transparent. The input to the LED may be automatically generated by the control circuit in response to detecting a state of the smoking article. If desired, the control body may include an LED disposed at a distal end of the shell.

In another embodiment, a control body for an electronic smoking article can include an elongated shell having an interior, a proximal end, and an opposing distal end. The control body can further include a coupler formed as an elongated body having a first end defining a wall and engaging the proximal end of the shell, and a second end including a cavity configured to releasably engage with a cartridge, the coupler having a pressure channel extending between the first end in fluid communication with the cavity and a second end opening through the wall at the first end of the coupler, the coupler having an air inlet channel in fluid communication with the cavity and an air inlet opening in an outer surface of the coupler, the coupler having a longitudinal axis extending from the first end to the second end, the first end of the pressure channel being spatially separated from the air inlet channel with respect to the longitudinal axis of the coupler. The control body can further include one or more additional components, such as a power source, a microprocessor, or other control components. In some embodiments, the first end of the pressure channel within the coupler can be spatially separated from the air inlet channel so as to be relatively closer to the second end of the coupler.

In a further embodiment, the present invention can provide an electronic smoking article. The smoking article can include a cartridge comprising a control body as described herein, and an aerosol precursor composition and a heater configured to vaporize the aerosol precursor composition.

The present invention includes the following examples without limitation.

Example 1: A control body for an electronic smoking article, said control body comprising:

An elongated shell having an inner, proximal end, and an opposite distal end;

A coupler having a body end that engages with the proximal end of the shell and an opposing connector end configured to releasably engage with the cartridge;

Power; and

An electronic circuit board is included which is placed between the power supply and the coupler within the shell.

The shell has a central axis extending through the shell from the proximal end to the distal end, and the electronic circuit board is oriented substantially parallel to the central axis of the shell.

Embodiment 2: The control body of any preceding or subsequent embodiment further comprising a pressure sensor attached to the electronic circuit board.

Embodiment 3: In the control body of any preceding or subsequent embodiment, the interior of the shell has a pressure-sensitive space and a pressure-sensitive space, and a first end of the pressure sensor is in fluid communication with the pressure-sensitive space and a second end of the pressure sensor is in fluid communication with the pressure-sensitive space.

Embodiment 4: In the control body of any preceding or subsequent embodiment, the body end of the coupler forms a wall, the connector end of the coupler has a cavity, and the coupler has a pressure channel extending between a first end in fluid communication with the cavity and a second end opening through the wall at the body end of the coupler to be in fluid communication with the depressurized space.

Example 5: In the control body of any preceding or subsequent embodiment, the pressure channel is integrally formed within the coupler.

Example 6: In the control body of any preceding or subsequent embodiment, a sealing member is configured to form a hermetic seal around the pressure sensor and the second end of the pressure channel, thereby forming a depressurized space surrounding the opening in the second end of the pressure channel and the first end of the pressure sensor.

Example 7: In the control body of any preceding or subsequent embodiment, the sealing member is in physical contact with the inner surface of the shell.

Example 8: In the control body of any preceding or subsequent embodiment, the coupler has an air inlet channel in fluid communication with the cavity.

Example 9: In the control body of any preceding or subsequent embodiment, the air inlet channel is formed entirely within the coupler body.

Example 10: In the control body of any preceding or subsequent embodiment, the coupler comprises an air inlet opening in fluid communication with the air inlet on the outer surface thereof.

Example 11: In the control body of any preceding or subsequent embodiment, the coupler has a longitudinal axis extending from the body end to the opposing connector end, and the first end of the pressure channel is spatially separated from the air inlet channel with respect to the longitudinal axis of the coupler.

Example 12: In the control body of any preceding or subsequent embodiment, the first end of the pressure channel is spatially separated from the air inlet channel so as to be relatively closer to the connector end of the coupler.

Example 13: In the control body of any preceding or subsequent embodiment, an ambient air flow path extending from the exterior of the coupler, through the coupler body, and through the cavity.

Example 14: In the control body of any preceding or subsequent embodiment, the electronic circuit board comprises a microprocessor, the microprocessor being configured to establish a current flow from the power source when the pressure sensor detects a reduced pressure within the reduced pressure space relative to the pressure within the normal pressure space.

Example 15: In the control body of any preceding or subsequent embodiment, the electronic circuit board is disposed entirely within the atmospheric pressure space.

Example 16: A control body of any preceding or subsequent embodiment, comprising one or more light emitting diodes (LEDs) attached to an electronic circuit board.

Example 17: In the control body of any preceding or subsequent embodiment, at least a portion of the coupler is optically transmissive such that light from the LED is visible through the coupler.

Example 18: In the control body of any preceding or subsequent embodiment, the control circuit is configured to cause one or more LEDs to emit a predetermined illumination signal corresponding to a state of the electronic smoking article.

Example 19: In the control body of any preceding or subsequent embodiment, comprising an input element, wherein the control circuit is configured to cause one or more LEDs to emit a determined illumination signal in response to input from the input element.

Example 20: In the control body of any preceding or subsequent embodiment, the input element is at least partially optically transparent.

Example 21: An electronic smoking article comprising a control body of any preceding or subsequent embodiment, and a cartridge comprising an aerosol precursor composition and a heater configured to vaporize the aerosol precursor composition.

Example 22: A control body for an electronic smoking article, said control body comprising:

An elongated shell having an inner, proximal end, and an opposite distal end;

A coupler formed of an elongated body having a first end that forms a wall and engages with a proximal end of the shell and a second end that includes a cavity configured to releasably engage with the cartridge; and

Containing a microprocessor,

The coupler has a pressure channel extending between a first end in fluid communication with the cavity and a second end opening through a wall at the first end of the coupler, the coupler has an air inlet channel in fluid communication with the cavity and an air inlet opening in an outer surface of the coupler, the coupler has a longitudinal axis extending from the first end to the second end, the first end of the pressure channel being spatially separated from the air inlet channel with respect to the longitudinal axis of the coupler.

The above and other features, aspects and advantages of the present invention will become apparent from a careful reading of the following detailed description taken in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four or more of the above embodiments as well as any combination of any two, three, four or more of the features or elements disclosed herein, regardless of whether such features or elements are explicitly combined in a particular embodiment description herein. The present invention is intended to be interpreted collectively and thus any individual feature or element of the present invention should be considered to be combinable in any of its various aspects and embodiments unless expressly stated otherwise.

Having described the present invention in general terms above, reference will now be made to the accompanying drawings, which are not necessarily to scale.
Figure 1 is a cross-sectional view of an electronic smoking article including a control body and a cartridge.
FIG. 2 is a cross-sectional view of an electronic smoking article including a cartridge and a control body according to an exemplary embodiment of the present invention.
FIG. 3 is a cross-sectional view of a control body of an electronic smoking article according to an exemplary embodiment of the present invention.
Figure 4 is a detailed drawing of the proximal end of the control body illustrated in Figure 3.
Figure 5 is a detailed drawing of the proximal end of the control body shown in Figure 3, which also shows a sealing member.
Fig. 6a is a cross-sectional view taken along line AA of Fig. 5.
Fig. 6b is a cross-sectional view through line BB of Fig. 5.
FIG. 7 is a partial cross-sectional view of an electronic smoking article according to a further exemplary embodiment of the present invention showing a control body connected to a cartridge via a control body coupler and a cartridge base.
FIG. 8 is a cross-sectional view of a proximal end of a control body of an electronic smoking article according to a further exemplary embodiment of the present invention illustrating an input element.
FIG. 9 is a perspective view of an electronic smoking article according to an exemplary embodiment of the present invention showing a control body attached to a cartridge via an optically transparent coupler.

Hereinafter, the present invention will be more fully described with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In fact, the present invention may be embodied in many different forms and should not be considered limited to the embodiments set forth herein; rather, these embodiments are provided so that the present invention can satisfy applicable legal requirements. As used in the specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

The present invention provides a description of an aerosol delivery device or smoking article, such as a so-called "electronic cigarette." It should be appreciated that the devices, components, features and methods may be embodied in many different forms and may be associated with a variety of articles.

In this regard, the present invention provides a description of an aerosol delivery device that uses electrical energy to heat a material (preferably without significantly burning or pyrolyzing the material) to form an inhalable substance; most preferably, such an article is compact enough to be considered a "handheld" device. The aerosol delivery device may provide some or all of the sensations of smoking a cigarette, cigar, or pipe (e.g., the act of breathing, the form of flavor or aroma, the sensory effects, the body sensation, the act of using, the visual cues such as those provided by a visible aerosol, etc.) without significantly burning or pyrolyzing any component of the article or device. The aerosol delivery device may not generate smoke in the sense of an aerosol resulting from the combustion or pyrolysis of tobacco, but rather the article or device may produce a vapor resulting from the volatilization or evaporation of certain components of the article or device (including a vapor within the aerosol that may be considered to be a visible aerosol that may be considered to be described as being similar to smoke). In a very preferred embodiment, the aerosol delivery device may comprise tobacco and/or tobacco-derived components.

The aerosol delivery device of the present invention may also be characterized as a vapor-generating article, a smoking article, or a drug delivery article. Accordingly, such an article or device may be configured to provide one or more substances (e.g., a flavoring agent and/or a pharmaceutical active ingredient) in an inhalable form or state. For example, the inhalable substance may be provided substantially in the form of a vapor (i.e., a substance that is gaseous at a temperature below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For simplicity, the term "aerosol" as used herein is meant to include vapors, gases, and aerosols in any form or type suitable for inhalation by a human being, whether or not visible, and whether or not in a form that can be considered to resemble smoke.

In use, the aerosol delivery device according to the present invention can be adapted to accommodate a variety of physical actions of an individual when using a traditional smoking article (e.g., a cigarette, cigar, or pipe used by lighting and inhaling the tobacco). For example, a user of the aerosol delivery device of the present invention can hold the article much like a traditional smoking article, bite an end of the article to inhale the aerosol produced by the article, take puffs at selected time intervals, and so on.

The aerosol delivery device of the present invention generally comprises a number of components provided within an outer body or shell. The overall design of the outer body or shell may be varied, and the format or structure of the outer body, which may define the overall size and shape of the aerosol delivery device, may be varied. Typically, the elongated body, resembling the shape of a cigarette or cigar, may be formed as a single integral shell; or the elongated body may be formed of two or more separable pieces. For example, the aerosol delivery device may comprise an elongated shell or body that may be substantially tubular in shape, thus resembling the shape of a conventional cigarette or cigar. In one embodiment, all of the components of the aerosol delivery device are housed within the outer body or shell. Alternatively, the aerosol delivery device may comprise two or more shells that may be joined and separated. For example, one end of the aerosol delivery device may have an outer body or shell that accommodates one or more reusable components (e.g., a rechargeable battery and various electronics for controlling operation of the article), and the other end may have an outer body or shell that is removably attached that accommodates a disposable portion (e.g., a disposable flavorant-receiving cartridge). More specific formats, configurations, and arrangements of the components within a single-shell type unit or within a multi-piece separate shell type unit will be apparent in view of the additional description provided herein. Furthermore, various aerosol delivery device designs and component structures can be understood in light of existing electronic aerosol delivery devices, such as the representative products enumerated in the Background of the Invention section.

The aerosol delivery device of the present invention most preferably comprises some combination of a power source (i.e., an electrical power source), one or more control components (e.g., means for manipulating, controlling, regulating and/or terminating power for heating, such as by controlling the flow of current from the power source to other components of the article, e.g., a microcontroller), a heater or heating component (e.g., an electrical resistance heating element or component, collectively referred to as an "atomizer"), an aerosol precursor composition (e.g., a liquid capable of generating an aerosol when sufficiently heated, such as those collectively referred to as "smoke juice", "e-liquid" and "e-juice"), and a mouth end region or tip for enabling the aerosol delivery device to be bitten for inhalation of the aerosol (e.g., an airflow path formed through the article such that when bitten, the generated aerosol can be withdrawn from the article). Exemplary formulations for aerosol precursor materials that may be used in accordance with the present invention are described in U.S. Patent Publication No. 2013/0008457 to Zheng et al. and U.S. Patent Application No. 13/536,438 to Sebastian et al., filed Jun. 28, 2012, which are incorporated herein by reference in their entireties.

The arrangement of components within the aerosol delivery device may be varied. In certain embodiments, the aerosol precursor composition may be positioned near an end of the article that may be proximate to the user's mouth (e.g., within a cartridge that may be replaced and discarded in certain circumstances) to maximize aerosol delivery to the user. However, other configurations are not excluded. In general, the heating element may be positioned sufficiently proximate the aerosol precursor composition such that heat from the heating element can volatilize the aerosol precursor (as well as one or more flavorants, medications, etc. that may be provided for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor composition, the aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be appreciated that the above terms "emission," "emitting," "emitting," or "emitted" are interchangeable to include "forming or occurring," "forming or occurring," "forming or occurring," and "is formed or occurring." Specifically, the inhalable substance is emitted in the form of a vapor or an aerosol or a mixture thereof. Furthermore, given the commercially available electronic aerosol delivery devices, such as the representative products listed in the Background section of the present invention, one can see a variety of aerosol delivery device components to choose from.

The aerosol delivery device includes a battery or other electrical power source to provide sufficient current flow to provide various functions to the article, such as resistive heating, powering a control system, powering an indicator, etc. The power source can take various embodiments. Preferably, the power source can deliver sufficient power to rapidly heat the heating element to provide aerosol formation and power the article through use over a period of time. The power source is preferably sized to fit snugly within the aerosol delivery device so that the aerosol delivery device can be easily handled; furthermore, the power source is preferably lightweight enough not to detract from the desirable smoking experience.

An exemplary embodiment of an aerosol delivery device (100) is provided in FIG. 1. As illustrated in the cross-sectional view of FIG. 1, the aerosol delivery device (100) may include a control body (102) and a cartridge (104) that may be permanently or removably aligned in a functional relationship. While a screw connection is illustrated in FIG. 1, it should be appreciated that additional coupling means may be used, such as a press-fit connection, an interference fit, a magnetic coupling, and the like. In particular, connecting components such as those further described herein may be used. For example, the control body may include a coupler configured to mate with a connector on the cartridge. Such couplers and connectors are further discussed herein.

In certain embodiments, one or both of the control body (102) and the cartridge (104) may be referred to as disposable or reusable. For example, the control body may have a replaceable battery or a rechargeable battery and thus may be combined with any form of recharging technology, including connection to a conventional electrical outlet, connection to an automobile charger (i.e., a cigarette lighter), and connection to a computer via a USB cable, etc. For example, an adapter having a USB connector on one end and a control body connector on the opposite end is disclosed in U.S. patent application Ser. No. 13/840,264, filed Mar. 15, 2013, which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the cartridge may comprise a disposable cartridge as disclosed in U.S. patent application Ser. No. 13/603,612, filed Sep. 5, 2012, which is incorporated herein by reference in its entirety.

In an exemplary embodiment, the control body (102) comprises a variably arranged control component (106) (e.g., a microcontroller), a flow sensor (108), and a battery (110), and may have a plurality of indicators (112) at a distal end (114) of the outer body (116). The indicators (112) may be provided in a variable number, may take on a variety of shapes, and may be openings within the body (e.g., for emitting a sound when such indicators are present). In an exemplary embodiment, a tactile feedback component (101) is provided with the control component (106). Thus, the tactile feedback component may be integrated with one or more components of the smoking article to provide a vibration or similar tactile indication of use or status to the user. See, for example, U.S. patent application Ser. No. 13/946,309, filed Jul. 19, 2013, to Galloway et al., which is incorporated herein by reference in its entirety.

An air intake (118) may be positioned on the outer body (116) of the control body (102). A coupler (120) may also be provided on the proximal attachment end (122) of the control body (102) that may extend into the control body projection (124) to facilitate electrical connection with the atomizer or a component thereof, such as a resistive heating element (described below), when the cartridge (104) is attached to the control body. While the air intake (118) is shown as being provided on the outer body (116), in other embodiments the air intake may be provided within the coupler, for example as described in U.S. patent application Ser. No. 13/841,233, filed Mar. 15, 2013, to DePiano et al.

The cartridge (104) has an outer body (126) having a mouth opening (128) provided at its mouth end (130) to allow air and entrained vapor (i.e., inhalable components of the aerosol precursor composition) to pass from the cartridge to the consumer while the aerosol delivery device (100) is inflated. The aerosol delivery device (100) may in some embodiments be substantially rod-shaped, substantially tubular, or substantially cylindrical. In other embodiments, additional shapes and dimensions are contemplated, such as, for example, rectangular or triangular cross sections.

The cartridge (104) further includes an atomizer (132) comprising a resistive heating element (134) configured to generate heat (e.g., a wire coil) and a liquid transport element (136) configured to transport a liquid (e.g., a wick). Various embodiments of materials configured to generate heat when an electric current is applied thereto may be used to form the resistive heating element (134). Exemplary materials that may form the wire coil include kanthal (FeCrAl), nichrome, molybdenum disiliconide (MoSi ₂ ), molybdenum siliconide (MoSi), aluminum-doped molybdenum disiliconide (Mo(Si,Al) ₂ ), and ceramics (e.g., positive temperature coefficient ceramics). In addition to the above, exemplary heating elements and materials for use therewith are disclosed in U.S. Patent Nos. 5,060,671 to Counts et al.; 5,093,894 to Deevi et al.; No. 5,224,498 to Deevi et al.; No. 5,228,460 to Sprinkel II et al.; No. 5,322,075 to Deevi et al.; No. 5,353,813 to Deevi et al.; No. 5,468,936 to Deevi et al.; No. 5,498,850 to Das; No. 5,659,656 to Das; No. 5,498,855 to Deevi et al.; No. 5,530,225 to Hajaligol; No. 5,665,262 to Hajaligol; No. 5,573,692 to Das et al.; and No. 5,591,368 to Fleischhauer et al.

Conductive heater terminals (138) (e.g., positive and negative terminals) at opposite ends of the heating element (134) are configured to conduct current through the heating element to form an electrical connection between the heating element and the battery (110) when the cartridge (104) is connected to the control body (102) and are configured to be attached to suitable wiring or circuitry (not shown). Specifically, a plug (140) may be disposed at the distal attachment end (142) of the cartridge (104). When the cartridge (104) is connected to the control body (102), the plug (140) engages the coupler (120) to form an electrical connection to controllably allow current to flow from the battery (110) through the coupler and plug to the heating element (134). The outer body (126) of the cartridge (104) may continue across the distal attachment end (142) such that this end of the cartridge is substantially closed by a plug (140) protruding therefrom.

A liquid transport element may be combined with a reservoir to transport the aerosol precursor composition to the aerosolization zone. In the embodiment illustrated in FIG. 1, the cartridge (104) has a reservoir layer (144) comprising a layer of nonwoven fibers formed in the shape of a tube surrounding the interior of the outer body (126) of the cartridge in this embodiment. The aerosol precursor composition is retained within the reservoir layer (144). For example, the liquid component may be retained by adsorption by the reservoir layer (144). The reservoir layer (144) is in fluid communication with the liquid transport element (136). The liquid transport element (136) transports the aerosol precursor composition stored in the reservoir layer (144) to the aerosolization zone (146) of the cartridge (104) via capillary action. As illustrated, the liquid transport element (136) is in direct contact with the heating element (134), which in this embodiment is in the form of a metal wire coil.

It should be appreciated that aerosol delivery devices that can be manufactured in accordance with the present invention may include various combinations of components useful for forming electronic aerosol delivery devices. See, for example, U.S. patent application Ser. No. 13/536,438, filed Jun. 28, 2012, entitled Reservoir and Heater System for Controlled Delivery of Multiple Aerosolizable Materials in an Electronic Smoking Article, which is incorporated herein by reference in its entirety. Additionally, U.S. patent application Ser. No. 13/602,871, filed Sep. 4, 2012, to Collett et al., which is incorporated herein by reference in its entirety, discloses an electronic smoking article having a microheater.

Also see U.S. Patent Publication No. 2013/0213419 to Tucker et al., which discloses a ribbon of electrically resistive mesh material that can be wound around a wick, and U.S. Patent Publication No. 2013/0192619 to Tucker et al., which discloses a heater coil around a wick with coil turns having substantially uniform spacing between each turn. In certain embodiments according to the present invention, the heater may comprise metal wire that can be wound around a liquid transport element, such as a wick, at a variable pitch. Exemplary variable pitch heaters that may be used according to the present invention are described in U.S. Patent Application Serial No. 13/827,994 to DePiano et al., filed Mar. 14, 2013, which is herein incorporated by reference in its entirety.

Also reference is made to a liquid supply reservoir formed of an elastomeric material and configured to be manually compressed for pumping a liquid substance therefrom, as disclosed in U.S. Patent Publication No. 2013/0213418 to Tucker et al. In certain embodiments according to the present invention, the reservoir may be formed of a fibrous material, such as a fibrous mat or tube capable of absorbing or adsorbing a liquid substance in particular.

In another embodiment, substantially all of the cartridge may be formed of one or more carbon materials, which may provide advantages in terms of biodegradability and absence of wire. In this regard, the heating element may comprise carbon foam, the reservoir may comprise carbonized fabric, and graphite may be used to form electrical connections with the battery and controller. Such carbon cartridges may be combined with one or more of the elements described herein to provide illumination of the cartridge in some embodiments. Illustrative embodiments of carbon-based cartridges are provided in U.S. Patent Publication No. 2013/0255702 to Griffith II et al., which is incorporated herein by reference in its entirety.

In use, when the user inhales the article (100), the heating element (134) is activated (e.g., via a flow sensor, etc.) and the components for the aerosol precursor composition are vaporized in the aerosolization zone (146). Inhalation of the mouth end (130) of the article (100) causes ambient air to enter the air intake port (118) and pass through the central opening in the coupler (120) and the central opening in the plug (140). In the cartridge (104), the inhaled air passes through the air passage (148) in the air passage tube (150) and combines with the vapor formed in the aerosolization zone (146) to form an aerosol. The aerosol is moved away from the aerosolization zone (146), passes through the air passage (152) within the air passage tube (154), and out the mouth opening (128) of the mouth end (130) of the article (100).

The various components of the aerosol delivery device according to the present invention can be selected from those described in the background art and those available commercially. Examples of batteries that can be used according to the present invention are described in U.S. Patent Publication No. 2010/0028766 to Peckerar et al., which is incorporated herein by reference in its entirety.

An exemplary device that may provide puff-actuated capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, 111. Additional examples of demand-actuated electrical switches that may be employed in the heating circuit according to the present invention are described in U.S. Patent No. 4,735,217 to Gerth et al., which is incorporated herein by reference in its entirety. Additional descriptions of current regulating circuits and other control components, including microcontrollers, that may be useful in the present aerosol delivery devices are provided in U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., and U.S. Patent No. 7,040,314 to Nguyen et al., all of which are herein incorporated by reference in their entireties.

Also, reference is made to International Publication Nos. WO 2013/098396 to Talon, WO 2013/098397 to Talon, and WO 2013/098398 to Talon which describe controllers configured to control power supplied to a heater element from a power source as a means for monitoring the condition of the device, such as heater temperature, airflow past the heater, and the presence of aerosol forming material in the vicinity of the heater. In certain embodiments, the present invention provides various control systems configured to monitor condition indicators, such as via communication between a microcontroller within the control body and a microcontroller or other electronic component within the cartridge component.

The aerosol precursor, which may also be referred to as an aerosol precursor composition or vapor precursor composition, may comprise one or more different components. For example, the aerosol precursor may comprise a polyhydric alcohol (e.g., glycerin, propylene glycol, or mixtures thereof). Representative examples of additional aerosol precursor compositions are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh II et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; WO 98/57556 to Biggs et al.; and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988), which are incorporated herein by reference in their entireties.

Other components may be used in the aerosol delivery device of the present invention. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator that may be used in a smoking article; U.S. Patent No. 5,261,424 to Sprinkel II discloses a piezoelectric sensor that may be associated with the mouth-end of the device to detect user lip activity associated with puffing and subsequently trigger heating; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling the flow of energy to a heating rod array in response to a pressure drop across the mouthpiece; U.S. Patent No. 5,967,148 to Harris et al. discloses a receptacle within a smoking device having an identifier that detects non-uniformity in the infrared transmittance of an inserted component and a controller that executes a detection routine as the component is inserted into the receptacle; No. 6,040,560 to Fleischhauer et al. describes a controlled executable power cycle having multiple differential phases; No. 5,934,289 to Watkins et al. discloses a photonic-optoelectronic component; No. 5,954,979 to Counts et al. discloses a means for varying the smoking resistance through a smoking device; No. 6,803,545 to Blake et al. discloses a particular battery structure for use in a smoking device; No. 7,293,565 to Griffen et al. discloses various charging systems for use in a smoking device; No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and enable computer control of the device; and No. 2010/0163063 to Fernando et al. discloses an identification system for a smoking device; WO 2010/003480 to Flick discloses a fluid flow sensing system for indicating a puff within an aerosol generating system; all of which are incorporated herein by reference in their entirety. Additional examples of components related to electronic aerosol delivery articles and disclosed materials or components that can be used in the articles of the present invention include: U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,388,574 to Ingebrethsen; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; No. 7,832,410 to Hon; No. 7,513,253 to Kobayashi; No. 7,896,006 to Hamano; No. 6,772,756 to Shayan; No. 8,156,944 to Hon; No. 8,365,742 to Hon; No. 8,375,957 to Hon; No. 8,393,331 to Hon; Nos. 2006/0196518 and 2009/0188490 to Hon; No. 2009/0272379 to Thorens et al.; No. 2009/0260641 and 2009/0260642 to Monsees et al. U.S. Patent Publication Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.; U.S. Patent Publication No. 2010/0307518 to Wang; and WO 2010/091593 to Hon; WO 2013/089551 to Foo; and U.S. Patent Publication No. 2013/0037041 to Worm et al., each of which is incorporated herein by reference in its entirety. Various materials disclosed in the foregoing references can be incorporated into various embodiments of the present devices, all of which are incorporated herein by reference in their entireties.

The above description of the use of the article may be applied to various embodiments described herein with minor modifications that would be apparent to those skilled in the art in light of the additional teachings provided herein. However, the description of the use is not intended to limit the uses of the article, but is provided so as to meet all necessary requirements of the present disclosure.

In various embodiments according to the present invention, electronic smoking articles, particularly cartridges thereof, may include a reservoir housing that may be used in addition to or in the absence of a porous medium. For example, a porous medium, such as a fibrous mat material, may be present within the reservoir housing. Alternatively, the reservoir housing may form a reservoir without any porous medium within the reservoir housing. Electronic smoking articles comprising reservoir housings are described, inter alia, in U.S. patent application Ser. No. 14/087,594, filed Nov. 22, 2013, which is incorporated herein by reference in its entirety.

Any of the elements shown in Figure 1 or shown in the articles described above may be incorporated into a smoking article according to the present invention. In particular, any of the components of the control body described and illustrated above may be incorporated into a control body according to the present invention.

An exemplary embodiment of a smoking article (200) according to the present invention is illustrated in FIG. 2. As illustrated, a control body (202) may be formed of a control body shell (201) which may include a control component (206), a flow sensor (208), a battery (210), and an LED (212). A cartridge (204) may be formed of a cartridge shell (203) which encloses a reservoir housing (244) in fluid communication with a liquid transport element (236) configured to wick or otherwise transport an aerosol precursor composition stored in the reservoir housing to a heater (234). An opening (228) may be present in the cartridge shell (203) to allow the formed aerosol to be expelled from the cartridge (204). These components are representative of components that may be present in a cartridge and are not intended to limit the scope of cartridge components encompassed by the present invention.

Although the control component (206) and the flow sensor (208) are shown separately, it should be noted that the control component and the flow sensor may be combined as an electronic circuit board to which the air flow sensor is directly attached. Furthermore, the electronic circuit board may be arranged horizontally with respect to the illustration in FIG. 2 in that the electronic circuit board may be longitudinally parallel to the central axis of the control body.

The cartridge (204) may also include one or more electronic components (250), which may include ICs, memory components, sensors, etc. The electronic components (250) may be configured to communicate with the control component (206).

The control body (202) and the cartridge (204) may have components configured to facilitate fluid coupling therebetween. As illustrated in FIG. 2, the control body (202) may have a coupler (224) having a cavity (225) provided therein. The cartridge (204) may have a base (240) configured to couple with the coupler (224) and may have a protrusion (241) configured to fit within the cavity (225). This coupling may not only facilitate a stable connection between the control body (202) and the cartridge (204), but may also establish an electrical connection between the battery (210) and the control component (206) within the control body and the heater (234) within the cartridge. Additionally, the control body shell (201) may have an air intake (218), which may be a notch in the shell, wherein the shell is connected to a coupler (224) to allow ambient air to move around the coupler and into the shell, whereupon the ambient air passes through the cavity (225) of the coupler and into the cartridge through the protrusion (241).

Useful couplers and bases according to the present invention are described in U.S. patent application Ser. No. 13/840,264, filed Mar. 15, 2013, which is incorporated herein by reference in its entirety. For example, the coupler illustrated in FIG. 2 may define an outer periphery (226) configured to mate with an inner periphery (242) of a base (240). In one embodiment, the inner periphery of the base may have a radius substantially equal to or slightly greater than a radius of the outer periphery of the coupler. Additionally, the coupler (224) may have one or more protrusions (229) on the outer periphery (226) configured to mate with one or more recesses (278) formed in the inner periphery of the base. However, various other embodiments of structures, shapes, and components may be used to couple the base to the coupler. In some embodiments, the connection between the base (240) of the cartridge (204) and the coupler (224) of the control body (202) may be substantially permanent, while in other embodiments the connection therebetween may be releasable, for example so that the control body can be discarded and/or refilled, allowing it to be reused with one or more additional cartridges.

The coupler may further include a plurality of electrical contacts configured to contact the terminals associated with the base projection. The electrical contacts may be positioned at different radial distances within the cavity (225) of the coupler (224) and may be positioned at different depths within the coupler. The depth and radius of each of the electrical contacts is configured such that when the base and the coupler are joined together to establish an electrical connection therebetween, an end of the terminal contacts the electrical contacts. For example, the first electrical contact may have a minimum diameter, the third electrical contact may have a maximum diameter, and the second electrical contact may have a diameter between them. Additionally, these electrical contacts may be positioned at different depths within the connector relative to the connector end. For example, the first electrical contact may be positioned at a maximum depth, the third electrical contact may be positioned at a minimum depth, and the second electrical contact may be positioned at a depth between them. These electrical contacts may include circular metal bands of variable depth that are positioned at different depths within the coupler. For example, see the electrical contacts illustrated in FIG. 4 .

In certain embodiments according to the present invention, the coupler utilized in the shell of the control body may be configured to provide additional or improved functionality, particularly with respect to communication between the coupler and the control components within the control body. This may be due to the specific structure of the electronic circuit board within the shell in relation to the coupler. For example, referring to FIG. 3 , a control body (302) useful in an electronic smoking article may include a shell (301) having an interior (303), a proximal end (322), and an opposing distal end (314). The control body (302) further includes a coupler (324) having a body end (324a) that engages with the proximal end (322) of the shell (301) and an opposing connector end (324b) that is configured to releasably engage with the cartridge. An end cap (311) is shown engaging the distal end (314) of the shell (301). The control body (302) also includes a battery (310), and an electronic circuit board (306) disposed within the interior (303) of the shell (301) between the battery (310) and the coupler (324). The electronic circuit board may include control circuitry, memory, a microprocessor, and/or the like. As illustrated in FIG. 3 , the shell (301) has a central axis extending along the length of the shell (301). In some embodiments, the electronic circuit board (306) may be oriented substantially parallel to the central axis of the shell (301), as illustrated in FIG. 3 . That is, the electronic circuit board may have a thickness and a length such that the length is greater than the thickness, and the electronic circuit board may be disposed longitudinally within the shell so as to be substantially parallel to the central axis of the shell. The electronic circuit board may be considered substantially parallel to the central axis of the shell when the alignment deviates less than 45 degrees, less than 30 degrees, or less than 15 degrees from parallel. In this arrangement, the functional surface(s) of the electronic circuit board to which the operating components may be attached face the shell walls, and thus the functional surface(s) of the electronic circuit board are substantially perpendicular to the central axis of the shell. In embodiments where the electronic circuit board is positioned substantially perpendicular to the central axis of the shell, the surface area of the electronic circuit board to which the components may be attached may be limited. However, as illustrated in FIG. 3, positioning the electronic circuit board substantially parallel to the central axis of the shell makes the most efficient use of the space within the shell and allows for increased surface area of the electronic circuit board for attachment of components such as microprocessors, LEDs, and other control components.

The electronic circuit board (306) may have a pressure sensor (308) directly attached thereto. Direct attachment in this sense is intended to mean a connection in which the pressure sensor is electrically connected to the electronic circuit board via an integrated component (e.g., pins) as opposed to a wired connection. Previous devices including a pressure sensor and an electronic circuit board typically have the pressure sensor spaced a significant distance from the electronic circuit board, with the electrical connection therebetween being formed using wires attached to the pressure sensor and the electronic circuit board. In the present configuration, the need for a wired connection between the electronic circuit board and the pressure sensor may be eliminated. This may reduce the cost associated with hand soldering the wired connection and may improve the reliability associated with the assembly process. In some embodiments, a direct connection may encompass the use of an intermediate attachment element or spacer (e.g., a spacer directly attached to the electronic circuit board and the pressure sensor directly attached to the spacer). Direct attachment may mean that the electrical contacts or pins of the pressure sensor are in direct contact with the electronic circuit board, although the body of the pressure sensor may be spaced from the electronic circuit board. Substantially direct attachment between the pressure sensor and the electronic circuit board can encompass any attachment that causes the body of the pressure sensor to be spaced from the electronic circuit board by less than 50% of the diameter of the shell (301), less than 25% of the diameter of the shell, less than 10% of the diameter of the shell, or less than 5% of the diameter of the shell. For example, the spacing can be less than 5 mm, less than 2 mm, or less than 1 mm. As illustrated, the pressure sensor (308) has a central axis extending between the first free end and the second end (308a and 308b, as illustrated in FIG. 5 ) attached to the electronic circuit board (306). This central axis of the pressure sensor (308) is substantially perpendicular to the central axis of the shell (301).

The positioning of the electronic circuit board is more clearly shown in the partial cross-sectional view illustrated in FIG. 4. As shown, the electronic circuit board (306) is positioned within the shell (301) between the battery (310) and the coupler (324) such that the longitudinal axis of the electronic circuit board is substantially parallel to the central axis of the shell. Thus, the electronic circuit board (306) has a first end (306a) adjacent the coupler (324) and a second end (306b) adjacent the battery (310). The electronic circuit board may be at least partially within the coupler. Thus, the electronic circuit board may be attached (e.g., force-fit, glued, or otherwise adhered) to the coupler. Alternatively, the electronic circuit board may be interconnected with the coupler via an intermediate attachment, such as an extension (361a) of the first electrical contact (361) (as discussed more fully below).

In the illustrated embodiment, the first end (306a) of the electronic circuit board (306) is disposed within the coupler (324), which may provide various advantages that will become apparent from the further disclosure herein. For example, such an arrangement may facilitate ease of connection between the electronic circuit board and the electrical contacts within the coupler. As illustrated in FIG. 4 , the first electrical contact (361), the second electrical contact (362), and the third electrical contact (363) are provided as a band surrounding a central opening (325) (or cavity) in the connector end (324b) of the coupler (324). Visible in FIG. 4 is an extension (361a) of the first electrical contact (361) that extends between the contact and the electronic circuit board (306) and passes through the coupler (324). A second electrical contact extension and a third electrical contact extension are also provided, but are not visible in the drawing.

The orientation of the electronic circuit board is also advantageous in that the interior (303) of the shell (301) can be partitioned into different spaces or sections that can experience different pressures. For example, the shell interior can have a pressure-attenuated space and a pressure-attenuated space. The pressure-attenuated space can be maintained at atmospheric pressure and can experience no significant change in pressure with respect to use of the control body within the electronic smoking article. The pressure-attenuated space can be maintained at ambient atmosphere by an opening within the shell (301). For example, the end cap (311) can be configured to allow communication between the pressure-attenuated space of the shell and the ambient atmosphere. This pressure communication between the pressure-attenuated space and the ambient atmosphere can be facilitated by an opening located anywhere on the shell (301) and/or around the connection of the coupler (324) to the shell. The reduced pressure space may be isolated from the normal pressure space, and the pressure within the reduced pressure space may be reduced below the pressure within the normal pressure space during use of the article (i.e., during suction of the article).

In the embodiment illustrated in FIG. 5, the first end (308a) of the pressure sensor (308) can be positioned in fluid communication with the reduced pressure space (383), and the second end (308b) of the pressure sensor can be positioned in fluid communication with the normal pressure space (373). In some embodiments, the reduced pressure space can be defined by a sealing member (380). For example, the sealing member can comprise silicone rubber or a similar material. In some embodiments, the sealing member can be a cup seal. The sealing member (380) can substantially surround the perimeter of the pressure sensor (308) and be in sealing contact therewith. As illustrated, the pressure sensor (308) is directly attached to the electronic circuit board (306), but the sealing member (380) does not extend completely the length of the pressure sensor and thus does not form sealing contact with the electronic circuit board. Accordingly, the second end (308b) of the pressure sensor (308) and the electronic circuit board (306) are placed within the atmospheric pressure space (373).

This structure is further illustrated in the cross-sectional view of FIG. 6a, where the pressure sensor (308) is directly attached to the electronic circuit board (306). A sealing member (380) surrounds the top and periphery of the pressure sensor (308), but does not contact the electronic circuit board (306). A gap “Y” between the sealing member (380) and the electronic circuit board (306) maintains the second end (308b) of the pressure sensor (308) within the pressure-sensitive space (373), while the first end (308a) of the pressure sensor is located within the pressure-sensitive space (383). To ensure that the second end (308b) of the pressure sensor (308) is maintained at atmospheric pressure, the direct connection of the pressure sensor to the electronic circuit board (306) may encompass the separation factors discussed herein. Accordingly, the second end (308b) of the pressure sensor (308) can be prevented from forming a hermetic seal with the electronic circuit board (306). Alternatively or in combination, an opening (307) may be formed in the electronic circuit board (306) near the second end (308b) of the pressure sensor (306) to provide pressure communication between the second end of the pressure sensor and the pressure space (373).

The coupler (324) may also have a pressure channel (385) that opens into the depressurized space (383). As illustrated in the embodiment of FIG. 5, the body end (324a) of the coupler (324) has a wall (324c) through which one or more openings or channels may pass. For example, the coupler wall (324c) may have a pressure channel (385) and an opening that accommodates the passage of an electrical contact extension. Thus, the body end (324a) of the coupler (324) may be described as having a wall (324c) through which the pressure channel (385) may extend.

The connector end (324b) of the coupler (324) has a cavity (325). The cavity (325) can be sized and shaped to receive a protrusion formed in the base of the cartridge (see FIG. 2). More specifically, the pressure channel can extend between a first end (385a) in fluid communication with the cavity (325) and a second end (385b) that opens through a wall (324c) at the body end (324a) of the coupler (324) to be in fluid communication with the depressurized space (383). The pressure channel can be integrally formed with the coupler, although other means of providing the channel are also contemplated. For example, a separate tube can be inserted through the coupler, or an opening can be created in the coupler body.

As illustrated in FIG. 5, the second end (385b) of the pressure channel (385) may protrude into the interior of the shell (301), and the sealing member (380) may substantially surround the periphery of the second end of the pressure channel. If desired, the second end (385b) of the pressure channel (385) may be flush with the wall (324c) at the body end (324a) of the coupler (324), and a sealing joint may be formed between the wall at the body end of the coupler and the sealing member (380) around the second end of the pressure channel. Preferably, the sealing member (380) is configured to form a hermetic seal around the first end (308a) of the pressure sensor (308) and the second end (385b) of the pressure channel (385). Accordingly, the depressurized space may surround the opening at the second end (385b) of the pressure channel and the first end (308a) of the pressure sensor (308). In some embodiments, the sealing member (380) may be in physical contact with the inner surface of the shell (301).

In some embodiments, the coupler (324) may have an air inlet channel (388) that may be configured to distribute inhaled ambient air through an electronic smoking article having the coupler. The air inlet channel (388) may be in fluid communication with, among other things, the cavity (325). Inhaled ambient air may enter the air inlet channel (388) through an air inlet opening (389) that opens through an outer surface of the coupler.

The structure of the air inlet channel (388) is further illustrated in the cross-sectional view of FIG. 6b, wherein the air inlet channel extends across the diameter of the coupler (324) between a first air inlet opening (389a) and a second air inlet opening (389b). These air inlet openings open through the outer surface of the coupler and provide an inlet for ambient air to be drawn into the coupler for distribution to other portions of an electronic smoking article utilizing the coupler. In other embodiments, the air inlet channel may extend only across a portion of the coupler, may branch, may open only as a single air inlet opening, or may open as more than two air inlet openings. In certain embodiments, the air inlet channel may be formed entirely within the coupler body.

In Fig. 6b, the pressure sensor (308) is visible through the pressure channel (385). Also visible through the pressure channel (385) is the inner surface of the sealing member (380) forming the depressurized space (383) at the first end (308a) of the pressure sensor (308). The cross-section of Fig. 6b additionally shows three openings (386a, 386b, 386c) through which the electrical contact extensions can pass.

As illustrated in FIG. 5, the first end (385a) of the pressure channel (385) extends beyond the air inlet channel (388) toward the connector end (324b) of the coupler (324). That is, the first end (385a) of the pressure channel (385) is positioned closer to the connector end (324b) of the coupler (324) than to the air inlet channel (388). This structure may be useful for preventing backflow of liquid or gas into the control body. The first end (385a) of the pressure channel (385) may also have a diameter smaller than the diameter of the second end (385b) of the pressure channel. Similarly, the pressure channel (385) may increase in diameter from its first end (385a) to its second end (385b).

Given the above structure, the coupler (324) may have an ambient airflow path therethrough. In some embodiments, the ambient airflow path may extend from the exterior of the coupler (324) (e.g., via one or more air inlet openings (389)), through the air inlet channels (388) of the coupler body (324), and through the cavity (325). The airflow path may also extend into a cartridge attached to the coupler (e.g., via a cartridge base, as shown in FIG. 2) and out of the cartridge, such as via openings in an opposite end thereof (see element (228) in FIG. 2).

The spatial relationship of the first end of the air inlet channel and the pressure channel is further illustrated in FIG. 7. As illustrated, the control body (702) is coupled to the cartridge (704) via a coupler (724) on the control body and a base (740) on the cartridge. The coupler (724) has a cavity (725) that receives a protrusion (741) on the base (740). As illustrated, each of the cavity (725) and the protrusion (741) has a stepped structure such that successively smaller diameter rings are present in the cavity and successively smaller diameter corresponding protrusion segments are present on the base. The protrusion (741) has an air flow inlet (741a) that seats in the cavity (725) of the coupler (724) near the air inlet channel (788). The coupler (724) further comprises a pressure channel (785) having a first end (785a) opening within the cavity (725) of the coupler and a second end (785b) opening within the control body (702), particularly within the depressurized space (783). The first end (785a) of the pressure channel (785) is spatially arranged relative to the air inlet channel (788) so as to be separated along the longitudinal axis of the coupler (724) (and thus also the shell (701) of the control body (702)). The longitudinal separation can be about 1 mm or more, about 2 mm or more, or about 3 mm or more.

When the cartridge (704) is coupled with the control body (702), air intake at the mouth end of the cartridge (see element (130) in FIG. 1) causes air to enter the air intake channels (788) of the coupler (724) through one or more air inlet openings (789) and into the air flow inlets (741a) of the protrusions (741), and the intaked air moves from the air flow inlets through the interior of the base (740) into the cartridge (704). Thus, air flow through the device can proceed downstream from the air inlet channels (788) toward the mouth end of the cartridge (704). The longitudinal separation of the first end (785a) of the pressure channel (785) and the air inlet channels (788) is such that the first end of the air inlet channels is downstream from the air inlet channels. That is, the first end (785a) of the pressure channel (785) and the air inlet channel (788) are spatially arranged and separated such that the first end of the pressure channel is relatively closer to the connector end (324b) of the coupler. Similarly, when the protrusion (741) of the base (740) engages with the cavity (725) of the coupler (724), the air flow inlet (741) is seated upstream within the cavity from the first end (785a) of the pressure channel (785). Accordingly, when the protrusion (740) engages with the cavity (725), the distance between the air flow inlet (741) and the first end (785a) of the pressure channel (785) may be about 1 mm or more, about 2 mm or more, or about 3 mm or more.

When suction of the device causing air to enter the air inlet channel (788) through the air inlet opening (789) causes a pressure drop, this pressure drop is communicated to the cavity (725). It is preferable that the matched structure of the cavity (725) and the protrusion (741) does not substantially form a hermetic connection therebetween. Accordingly, the pressure drop within the cavity (725) is likewise communicated from the first end (785a) to the second end (785b) of the pressure channel (785) and thus to the depressurized space (783). Due to the spatial arrangement of the air inlet channel (788) and the first end (785a) of the pressure channel (785), however, the air flow inlet (741) of the seated protrusion (740) is sufficiently spaced from the first end of the pressure channel to prevent or reduce the occurrence of liquid movement from the cartridge (704) through the base (740) into the control body (702).

In use, an individual may inhale through the mouth end of the cartridge (which may have a mouthpiece), and an airflow may be established along the airflow path as described above. The inhaled air enters the air inlet channel through the air inlet opening. The air inlet channel may restrict the airflow such that the pressure within the coupler is lower than the ambient pressure (and thus lower than the atmospheric pressure space within the control body shell). This reduced pressure is transmitted to a pressure sensor within the control body shell by the pressure channel formed in the coupler. In this manner, a pressure differential may be created across the pressure sensor between a first end of the pressure sensor within the reduced pressure space and a second end of the pressure sensor within the atmospheric pressure space within the shell. More specifically, the control circuit may be configured to establish a current flow from the electrical power source when the pressure sensor detects a reduced pressure within the reduced pressure space relative to the pressure within the atmospheric pressure space. This current flow may energize a heater within the cartridge to vaporize the aerosol precursor composition. By using a pressure channel, air entering the coupler does not need to pass through the control body shell, which would be required in a device having an air inlet formed in the shell of the control body.

As noted above, the spatial arrangement of the openings within the coupler may be beneficial in preventing any aerosol precursor composition from the cartridge from migrating into the interior of the control body. When the cartridge is attached to the control body, any aerosol formed within the cartridge that is not withdrawn by the user may condense. Likewise, water vapor may condense within the cartridge and/or liquid stored in a reservoir within the cartridge may leak within the cartridge. In some cases, such liquid may migrate from the cartridge through any air openings present to allow inhaled air to migrate from the control body to the cartridge. When an inlet for inhaled air is present in the control body shell, the airflow passage between the air inlet and the cartridge necessarily extends through at least a portion of the control body. Any liquid migrating out of the cartridge through the airflow passage may thus enter the control body, where it may contact a power source, pressure sensor, or control component of the device and cause damage to the control body.

However, according to the present invention, when the cartridge is coupled with the control body, the air flow inlet on the protrusion of the base of the cartridge is seated upstream from the first end of the pressure channel. Therefore, any liquid passing through the air flow inlet on the base protrusion of the cartridge will only enter the air inlet channel within the coupler, from which the liquid can either move out of the coupler through the air inlet opening or simply flow back into the cartridge.

Referring to FIG. 4, the electronic circuit board (306) may include various elements in addition to the pressure sensor (308). As illustrated, the electronic circuit board (306) additionally includes a first light emitting diode (LED) (312a) and a second LED (312b). A microprocessor, memory, etc. may also be present on the electronic circuit board. The electronic circuit board may include any elements suitable for establishing a control circuit suitable for controlling one or more functions of the electronic smoking article, etc.

In some embodiments, one or more LEDs on the electronic circuit board can be configured to emit light that is visible from outside the control body. For example, at least a portion of the control body shell and/or the coupler can be translucent or otherwise optically transmissive. An embodiment of the control body (802) illustrated in FIG. 8 includes an electronic circuit board (806) disposed within the shell (801) between the battery (810) and the coupler (824). The electronic circuit board (806) is configured longitudinally so as to be substantially parallel to a central axis of the shell (801). The electronic circuit board (806) includes a first LED (812a) and a second LED (812b). Additionally, in the illustrated embodiment, the coupler (824) is optically transmissive such that light from the first LED (812a) and/or light from the second LED (812b) is visible from outside the control body through the coupler. The coupler may be formed of, for example, a translucent thermoplastic material. The control body (802) may further comprise an input element, such as a pushbutton (861), which may be configured to activate power transmission from a power source within the control body to, for example, a heater within an attached cartridge (see FIG. 2). The input element may alternatively be configured to activate additional control functions of the device, such as those described in more detail below.

As illustrated in FIG. 9, when the control body (902) is attached to the cartridge (904), the coupler (924) forms a visible ring around the smoking article (900). When the LED on the electronic circuit board is activated, light is emitted through the coupler ring, as illustrated by the arrows in FIG. 9. The emitted light may be decorative in nature. In some embodiments, the control circuitry may be configured to cause one or more LEDs to emit a predetermined illumination signal corresponding to a state of the electronic smoking article.

The light signal may be formed by a color, a series of different colors, a single color or a series of different colors flashing light, or a specific number of flashes of a single color or a series of different colors. The state of the electronic smoking article may include any state, including but not limited to, a battery power state, a volume of aerosol precursor composition remaining in the cartridge, a number of puffs remaining in the cartridge, an operating state, an error code, heater activation, etc. The control circuit may be configured to automatically activate the light signal when a predetermined input is detected. For example, when the battery is half-powered, a power-down input may be received by the control circuit, and the control circuit may cause the LED to emit a predetermined light signal to alert the user of the battery condition. As a further non-limiting example, the predetermined light signal may be automatically activated whenever the user puffs on the device and activates the heater. The control element may include programming to automatically activate any number of light signals in response to an input. The input may be an electronic signal that is automatically generated in response to the programming of the control circuit.

In some embodiments, the control body may have an input element. The input element may be an element configured to be manually actuated by a user. The pushbutton (961) illustrated in FIG. 9 is an example of a manual input element. In other embodiments, the manual input element may be a resistive sensing device or a capacitive sensing device, including but not limited to a touchscreen. The manual input element may provide one or more inputs to the control circuit, which then transmits the inputs to the LED. The manual input may be configured to provide one or more inputs to generate an illumination signal indicating a state of the electronic smoking article. As a non-limiting example, a single push of the button or a tap of the touchscreen may generate an illumination signal indicating a battery state, and two rapid pushes of the button or successive taps of the touchscreen may generate an illumination signal indicating the number of puffs remaining in a cartridge attached to the control body. The control element may include programming to activate any number of illumination signals in response to various manual inputs to indicate different states of the device.

In some embodiments, the input element (e.g., a pushbutton) may be at least partially optically transparent. Thus, the illumination signal generated as described above may be visible not only through the input element but also through the coupler or instead of the coupler. For example, an illumination signal indicating one state may be visible through the input element, and an illumination signal indicating a second, different state may be visible through the coupler. If desired, LEDs may also be positioned at the distal end of the control body shell (see element (212) in FIG. 2), and such LEDs may likewise be configured to emit illumination signals.

Many modifications and other embodiments of the present invention will occur to those skilled in the art having the benefit of the teachings presented in the above description and the associated drawings. It is therefore to be understood that the invention is not to be limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the claims. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for a limiting purpose.

Claims (10)

In a control body for an electronic smoking device,
An elongated shell having an inner, proximal end, and an opposing distal end;
A coupler at least partially defining an air inlet channel, said coupler being configured to releasably engage with said cartridge such that air entering said air inlet channel is directed into an air flow path, said air flow path being formed along and on a central axis of said cartridge such that air can flow through a portion of the cartridge containing the inhalable substance;
A power source located inside the above elongated shell;
An electronic circuit board positioned inside the above elongated shell; and
comprising electrical contacts configured to establish an electrical connection from said power source to a device arranged to cause heating of the inhalable material of said cartridge;
The electrical contacts for establishing the electrical connection are arranged on the central axis of the cartridge and radially outside the air flow path formed along the central axis,
The air inlet channel of the above coupler is configured to be coupled with the air flow inlet of the air flow path within the cartridge so that, when coupled with the cartridge, air entering through the air inlet channel is directly introduced into the air flow path within the cartridge.
The above coupler further comprises at least one air inlet opening,
The air inlet channel of said coupler extends across at least a portion of said coupler from said air inlet opening without contacting said electrical contact.
Control body. In the first paragraph,
The above air inlet channel is formed throughout the coupler.
Control body. delete delete In the first paragraph,
comprising at least one light emitting diode (LED) attached to said electronic circuit board;
Control body. In paragraph 5,
At least a portion of the control body is light-transmitting so that light from the LED can be seen through the control body.
Control body. In paragraph 5,
The above electronic circuit board includes a control circuit,
The control circuit is configured to cause the at least one LED to emit a prescribed illumination signal corresponding to a state of the electronic smoking article.
Control body. In Article 7,
Contains input elements,
The control circuit is configured to cause the at least one LED to emit the prescribed lighting signal in response to an input from the input element.
Control body. In Article 8,
The above input element is at least partially optically transparent.
Control body. An electronic smoking article comprising a control body and a cartridge according to any one of claims 1, 2, and 5 to 9.